Method of producing structure containing phase-separated structure utilizing a brush composition comprising PS-PMMA

ABSTRACT

A brush composition used for phase-separation of a layer containing a block copolymer on a substrate, the brush composition including a resin component (N), the resin component (N) containing a hydrophobic structural unit (Nx) and a hydrophilic structural unit (Ny), the amount of the structural unit (Ny) within the resin component (N) being 5 mol % or less.

TECHNICAL FIELD

The present invention relates to a brush composition, and a method of producing a structure containing a phase-separated structure.

Priority is claimed on Japanese Patent Application No. 2014-246801, filed Dec. 5, 2014, the content of which is incorporated herein by reference.

DESCRIPTION OF RELATED ART

Recently, as further miniaturization of large scale integrated circuits (LSI) proceeds, a technology for processing a more delicate structure is demanded. In response to such demand, technical developments have been conducted on forming a fine structure using a phase-separated structure formed by self-assembly of block polymers having mutually incompatible blocks bonded together.

For using a phase separation of a block copolymer, it is necessary to form a self-organized nano structure by a microphase separation only in specific regions, and arrange the nano structure in a desired direction.

For realizing position control and orientational control of such self-assembled structure, methods such as graphoepitaxy to control phase-separated pattern by a guide pattern and chemical epitaxy to control phase-separated pattern by difference in the chemical state of the substrate are proposed (see, for example, Non-Patent Document 1).

As a method of phase-separating a block copolymer to form a fine pattern, for example, there is disclosed a method in which an intermediate layer having a surface free energy of a mean value of the surface free energy of 2 block chains is formed on a substrate, such that the face of the substrate contacting the block copolymer has a surface free energy of a mean value of the surface free energy of 2 block chains (for example, see Patent Literature 1). By forming such an intermediate layer on the substrate, the face of the substrate contacting the block copolymer has a surface free energy of a mean value of the surface free energy of 2 block chains.

In this manner, patterns of various shapes with smaller sizes can be formed as compared to conventional lithography properties.

DOCUMENTS OF RELATED ART Patent Literature

[Patent Document 1] Japanese Unexamined Patent Application, First Publication No. 2008-36491

Non-Patent Documents

[Non-Patent Document 1] Proceedings of SPIE (U.S.), vol. 7637, pp. 76370G-1 (2010)

SUMMARY OF THE INVENTION

However, in the method disclosed in Patent Literature 1, it was necessary to select a neutralization layer material which exhibit a surface free energy of predetermined value, depending on the kind of block copolymer used, so as to control the surface free energy of the neutralization layer. Therefore, there were demands for brush composition which can be used conveniently.

Further, conventional neutralization layer materials (brush compositions) had problems that it was difficult to control the surface state of the neutralization layer formed, and the phase separation of the block copolymer is likely to become poor.

The present invention takes the above circumstances into consideration, with an object of providing a brush composition which can improve the phase-separation performance of a block copolymer and can be conveniently used; and a method of producing a structure containing a phase-separated structure using the brush composition.

As a result of the studies of the present inventors, the present inventors have found that, when a fine structure is formed by directed self assembly (DSA) of a block copolymer, by improving the adhesion of the substrate and the layer containing a block copolymer formed on the substrate, the phase-separation of the block copolymer is promoted. As a result of further studies, the present inventors have found that, by adopting a specific resin component in the brush composition which can enhance the adhesiveness, the surface of the brush layer can be controlled to be at a highly hydrophobic state. The present invention has been completed based on this finding.

Specifically, a first aspect of the present invention is a brush composition used for phase-separation of a layer containing a block copolymer on a substrate, the brush composition including a resin component (N), the resin component (N) containing a hydrophobic structural unit (Nx) and a hydrophilic structural unit (Ny), the amount of the structural unit (Ny) within the resin component (N) being 5 mol % or less.

A second aspect of the present invention is a method of producing a structure containing a phase-separated structure, the method including: a step of applying the brush composition of the first aspect to form a layer of the brush composition; a step of forming a layer containing a block copolymer on the layer of the brush composition; and a step of phase-separating the layer containing the block copolymer.

In the present description and claims, the term “aliphatic” is a relative concept used in relation to the term “aromatic”, and defines a group or compound that has no aromaticity.

The term “alkyl group” includes linear, branched or cyclic, monovalent saturated hydrocarbon, unless otherwise specified.

The term “alkylene group” includes linear, branched or cyclic, divalent saturated hydrocarbon, unless otherwise specified. The same applies for the alkyl group within an alkoxy group.

A “halogenated alkyl group” is a group in which part or all of the hydrogen atoms of an alkyl group is substituted with a halogen atom. Examples of the halogen atom include a fluorine atom, a chlorine atom, a bromine atom and an iodine atom.

A “fluorinated alkyl group” or a “fluorinated alkylene group” is a group in which part or all of the hydrogen atoms of an alkyl group or an alkylene group have been substituted with a fluorine atom.

The term “structural unit” refers to a monomer unit that contributes to the formation of a polymeric compound (resin, polymer, copolymer).

A “structural unit derived from an acrylate ester” refers to a structural unit that is formed by the cleavage of the ethylenic double bond of an acrylate ester.

An “acrylate ester” refers to a compound in which the terminal hydrogen atom of the carboxy group of acrylic acid (CH₂═CH—COOH) has been substituted with an organic group.

The acrylate ester may have the hydrogen atom bonded to the carbon atom on the α-position substituted with a substituent. The substituent (R^(α)) with which the hydrogen atom bonded to the carbon atom at the α-position is substituted is an atom other than the hydrogen atom or a group, and examples thereof include an alkyl group having from 1 to 5 carbon atoms, a halogenated alkyl group having from 1 to 5 carbon atoms, and a hydroxyalkyl group. A carbon atom on the α-position of an acrylate ester refers to the carbon atom bonded to the carbonyl group, unless specified otherwise.

Hereafter, an acrylate ester having the hydrogen atom bonded to the carbon atom on the α-position substituted with a substituent is sometimes referred to as “α-substituted acrylate ester”. Further, acrylate esters and α-substituted acrylate esters are collectively referred to as “(α-substituted) acrylate ester”.

A “structural unit derived from hydroxystyrene or a hydroxystyrene derivative” refers to a structural unit that is formed by the cleavage of the ethylenic double bond of hydroxystyrene or a hydroxystyrene derivative.

The term “hydroxystyrene derivative” includes compounds in which the hydrogen atom at the α-position of hydroxystyrene has been substituted with another substituent such as an alkyl group or a halogenated alkyl group; and derivatives thereof. Examples of the derivatives thereof include hydroxystyrene in which the hydrogen atom of the hydroxy group has been substituted with an organic group and may have the hydrogen atom on the α-position substituted with a substituent; and hydroxystyrene which has a substituent other than a hydroxy group bonded to the benzene ring and may have the hydrogen atom on the α-position substituted with a substituent. Here, the α-position (carbon atom on the α-position) refers to the carbon atom having the benzene ring bonded thereto, unless specified otherwise.

As the substituent which substitutes the hydrogen atom on the α-position of hydroxystyrene, the same substituents as those described above for the substituent on the α-position of the aforementioned α-substituted acrylate ester can be mentioned.

A “structural unit derived from vinylbenzoic acid or a vinylbenzoic acid derivative” refers to a structural unit that is formed by the cleavage of the ethylenic double bond of vinylbenzoic acid or a vinylbenzoic acid derivative.

The term “vinylbenzoic acid derivative” includes compounds in which the hydrogen atom at the α-position of vinylbenzoic acid has been substituted with another substituent such as an alkyl group or a halogenated alkyl group; and derivatives thereof. Examples of the derivatives thereof include benzoic acid in which the hydrogen atom of the carboxy group has been substituted with an organic group and may have the hydrogen atom on the α-position substituted with a substituent; and benzoic acid which has a substituent other than a hydroxy group and a carboxy group bonded to the benzene ring and may have the hydrogen atom on the α-position substituted with a substituent. Here, the α-position (carbon atom on the α-position) refers to the carbon atom having the benzene ring bonded thereto, unless specified otherwise.

The term “styrene” is a concept including styrene and compounds in which the hydrogen atom at the α-position of styrene is substituted with other substituent such as an alkyl group and a halogenated alkyl group.

A “structural unit derived from styrene” or “structural unit derived from a styrene derivative” refers to a structural unit that is formed by the cleavage of the ethylenic double bond of styrene or a styrene derivative.

As the alkyl group as a substituent on the α-position, a linear or branched alkyl group is preferable, and specific examples include alkyl groups of 1 to 5 carbon atoms, such as a methyl group, an ethyl group, a propyl group, an isopropyl group, an n-butyl group, an isobutyl group, a tert-butyl group, a pentyl group, an isopentyl group and a neopentyl group.

Specific examples of the halogenated alkyl group as the substituent on the α-position include groups in which part or all of the hydrogen atoms of the aforementioned “alkyl group as the substituent on the α-position” are substituted with halogen atoms. Examples of the halogen atom include a fluorine atom, a chlorine atom, a bromine atom and an iodine atom, and a fluorine atom is particularly desirable.

Specific examples of the hydroxyalkyl group as the substituent on the α-position include groups in which part or all of the hydrogen atoms of the aforementioned “alkyl group as the substituent on the α-position” are substituted with a hydroxy group. The number of hydroxy groups within the hydroxyalkyl group is preferably 1 to 5, and most preferably 1.

The case of describing “may have a substituent” includes both of the case where the hydrogen atom (—H) is substituted with a monovalent group and the case where the methylene group (—CH₂—) is substituted with a divalent group.

The term “exposure” is used as a general concept that includes irradiation with any form of radiation.

By the brush composition of the present invention, the phase-separation performance of the block copolymer can be enhanced, and the brush composition can be conveniently used.

By the method of producing a structure containing a phase-separated structure according to the present invention, the phase-separation performance of the block copolymer can be enhanced, and a fine structure with a good shape can be formed, as compared to conventional lithography techniques.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram showing an example of one embodiment of the method of forming a structure containing a phase-separated structure according to the present invention.

FIG. 2 is an explanatory diagram showing an example of one embodiment of an optional step.

DETAILED DESCRIPTION OF THE INVENTION

<<Brush Composition>>

The present invention is a brush composition used for phase-separation of a layer containing a block copolymer on a substrate, the brush composition including a resin component (N), the resin component (N) containing a hydrophobic structural unit (Nx) and a hydrophilic structural unit (Ny), the amount of the structural unit (Ny) within the resin component (N) being 5 mol % or less.

(Block Copolymer)

A block copolymer is a polymeric compound in which plurality of partial constitutional components (blocks) in which the same kind of structural unit is repeatedly bonded are bonded. In the present invention, polymeric compound in which a hydrophobic polymer block (b11) and a hydrophilic polymer block (b21) bonded together may be preferably used as the block copolymer.

The hydrophobic polymer block (b11) (hereafter, referred to simply as “block (b11)”) refers to a block in which, when a plurality of monomers having different affinity relative to water are used, a monomer which exhibits relatively low affinity for water among the plurality of monomers is polymerized to form a polymer (hydrophobic polymer) as the block. The hydrophilic polymer block (b21) (hereafter, referred to simply as “block (b21)”) refers to a block in which a monomer which exhibits relatively high affinity for water among the plurality of monomers is polymerized to form a polymer (hydrophilic polymer) as the block.

The block (b11) and the block (b21) are not particularly limited as long as long as they are combinations capable of causing phase separation. However, it is preferable to use a combination of blocks which are mutually incompatible.

Further, as the block (b11) and the block (b21), it is preferable to use a combination in which a phase of at least one block amongst the plurality of blocks constituting the block copolymer can be reliably removed as compared to the phases of other blocks.

As the blocks constituting the block copolymer, 2 kinds of blocks may be used, or 3 or more kinds of blocks may be used.

In the present invention, the block copolymer may have a partial constitutional component (block) other than the block (b11) and the block (b21) bonded.

Examples of the block (b11) and the block (b21) include a block in which structural units derived from styrene or a styrene derivative are repeatedly bonded; a block in which structural units derived from an acrylate ester which may have the hydrogen atom bonded to the carbon atom on the α-position substituted with a substituent (structural units derived from (α-substituted) acrylate ester) are repeatedly bonded; a block in which structural units derived from acrylic acid which may have the hydrogen atom bonded to the carbon atom on the α-position substituted with a substituent (structural units derived from (α-substituted) acrylic acid) are repeatedly bonded; a block in which structural units derived from siloxane or a derivative thereof are repeatedly bonded; a block in which structural units derived from an alkyleneoxide are repeatedly bonded; and a block in which silsesquioxane structure-containing structural units are repeatedly bonded.

Examples of styrene derivatives include styrene, styrene in which the hydrogen atom on the α-position has been substituted with an alkyl group or a halogenated alkyl group, or derivatives thereof. Examples of such derivatives include styrene in which the hydrogen atom on the α-position may be substituted and has a substituent bonded to the benzene ring. Examples of the substituent include an alkyl group of 1 to 5 carbon atoms, a halogenated alkyl group of 1 to 5 carbon atoms and a hydroxyalkyl group.

Specific examples of styrene derivatives thereof include α-methylstyrene, 2-methylstyrene, 3-methylstyrene, 4-methylstyrene, 4-t-butylstyrene, 4-n-octylstyrene, 2,4,6-trimethylstyrene, 4-methoxystyrene, 4-t-butoxystyrene, 4-hydroxystyrene, 4-nitrostyrene, 3-nitrostyrene, 4-chlorostyrene, 4-fluorostyrene, 4-acetoxyvinylstyrene, and 4-vinylbenzylchloride.

Examples of (α-substituted) acrylate ester include an acrylate ester in which the hydrogen atom bonded to the carbon atom on the α-position is substituted with a substituent. Examples of the substituent include an alkyl group of 1 to 5 carbon atoms, a halogenated alkyl group of 1 to 5 carbon atoms and a hydroxyalkyl group.

Specific examples of the (α-substituted) acrylate ester include acrylate esters such as methyl acrylate, ethyl acrylate, propyl acrylate, n-butyl acrylate, t-butyl acrylate, cyclohexyl acrylate, octyl acrylate, nonyl acrylate, hydroxyethyl acrylate, hydroxypropyl acrylate, benzyl acrylate, anthracene acrylate, glycidyl acrylate, 3,4-epoxycyclohexylmethane acrylate, and propyltrimethoxysilane acrylate; and methacrylate esters such as methyl methacrylate, ethyl methacrylate, propyl methacrylate, n-butyl methacrylate, t-butyl methacrylate, cyclohexyl methacrylate, octyl methacrylate, nonyl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, benzyl methacrylate, anthracene methacrylate, glycidyl methacrylate, 3,4-epoxycyclohexylmethane methacrylate, and propyltrimethoxysilane methacrylate.

Examples of (α-substituted) acrylic acid include acrylic acid in which the hydrogen atom bonded to the carbon atom on the α-position is substituted with a substituent. Examples of the substituent include an alkyl group of 1 to 5 carbon atoms, a halogenated alkyl group of 1 to 5 carbon atoms and a hydroxyalkyl group.

Examples of (α-substituted) acrylic acid include acrylic acid and methacrylic acid.

Examples of siloxane and siloxane derivatives include dimethylsiloxane, diethylsiloxane, diphenylsiloxane, and methylphenylsiloxane.

Examples of the alkylene oxide include ethylene oxide, propylene oxide, isopropylene oxide and butylene oxide.

As the silsesquioxane structure-containing structural unit, polyhedral oligomeric silsesquioxane structure-containing structural unit is preferable. As a monomer which provides a polyhedral oligomeric silsesquioxane structure-containing structural unit, a compound having a polyhedral oligomeric silsesquioxane structure and a polymerizable group can be mentioned.

In the present invention, examples of the block copolymer include a polymeric compound in which a block having structural units derived from styrene or a styrene derivative repeatedly bonded, and a block having structural units derived from an (α-substituted) acrylate ester repeatedly bonded, are bonded together; a polymeric compound in which a block having structural units derived from styrene or a styrene derivative repeatedly bonded, and a block having structural units derived from an (α-substituted) acrylic acid repeatedly bonded, are bonded together; a polymeric compound in which a block having structural units derived from styrene or a styrene derivative repeatedly bonded, and a block having structural units derived from siloxane or a derivative thereof repeatedly bonded, are bonded together; a polymeric compound in which a block having structural units derived from alkyleneoxide repeatedly bonded, and a block having structural units derived from an (α-substituted) acrylate ester repeatedly bonded, are bonded together; a polymeric compound in which a block having structural units derived from alkyleneoxide repeatedly bonded, and a block having structural units derived from an (α-substituted) acrylic acid repeatedly bonded, are bonded together; a polymeric compound in which a block having structural units derived from having a polyhedral oligomeric silsesquioxane structure repeatedly bonded, and a block having structural units derived from an (α-substituted) acrylate ester repeatedly bonded, are bonded together; a polymeric compound in which a block having structural units derived from having a polyhedral oligomeric silsesquioxane structure repeatedly bonded, and a block having structural units derived from (α-substituted) acrylic acid repeatedly bonded, are bonded together; and a polymeric compound in which a block having structural units derived from structural units derived from having a polyhedral oligomeric silsesquioxane structure repeatedly bonded, and a block having structural units derived from siloxane or a derivative thereof repeatedly bonded, are bonded together.

Among these examples, as the block copolymer, a polymeric compound in which a block having structural units derived from styrene or a styrene derivative repeatedly bonded, and a block having structural units derived from an (α-substituted) acrylate ester repeatedly bonded, are bonded together; or a polymeric compound in which a block having structural units derived from styrene or a styrene derivative repeatedly bonded, and a block having structural units derived from an (α-substituted) acrylic acid repeatedly bonded, are bonded together is preferable; a polymeric compound in which a block having structural units derived from styrene or a styrene derivative repeatedly bonded, and a block having structural units derived from an (α-substituted) acrylate ester repeatedly bonded, are bonded together is more preferable; and a polymeric compound in which a block having structural units derived from styrene or a styrene derivative repeatedly bonded, and a block having structural units derived from a (meth)acrylate ester repeatedly bonded, are bonded together is still more preferable.

Specific examples thereof include a polystyrene-polymethyl methacrylate (PS-PMMA) block copolymer, a polystyrene-polyethyl methacrylate block copolymer, a polystyrene-(poly-t-butyl methacrylate) block copolymer, a polystyrene-polymethacrylic acid block copolymer, a polystyrene-polymethyl acrylate block copolymer, a polystyrene-polyethyl acrylate block copolymer, a polystyrene-(poly-t-butyl acrylate) block copolymer, and a polystyrene-polyacrylic acid block copolymer. Among these, a PS-PMMA block copolymer is most preferable.

The weight average molecular weight (Mw) (the polystyrene equivalent value determined by gel permeation chromatography) of each polymer constituting the block copolymer is not particularly limited as long as it is large enough to cause phase separation. The weight average molecular weight is preferably 5,000 to 500,000, more preferably 5,000 to 400,000, and still more preferably 5,000 to 300,000.

The weight average molecular weight (Mw) of the block copolymer is not particularly limited as long as it is large enough to cause phase separation. The weight average molecular weight is preferably 5,000 to 100,000, more preferably 20,000 to 60,000, and still more preferably 30,000 to 50,000.

The polydispersity (Mw/Mn) of the block copolymer is preferably 1.0 to 3.0, more preferably 1.0 to 1.5, and still more preferably 1.0 to 1.2. Here, Mn is the number average molecular weight.

The period of the block copolymer (the length of 1 molecule of the block copolymer) is preferably 5 to 50 nm, more preferably 10 to 40 nm, and still more preferably 20 to 30 nm.

In the present specification, a “period of a block copolymer” refers to a period of a phase structure observed when a phase-separated structure is formed, and is a sum of the lengths of the phases which are mutually incompatible. Specifically, in the case of forming a cylinder structure which has a phase-separated structure perpendicular to a surface of a substrate, the period of the block copolymer is the center distance (pitch) of two mutually adjacent cylinder structures.

The period of a block polymer is determined by intrinsic polymerization properties such as the polymerization degree N and the Flory-Huggins interaction parameter χ. Specifically, the repulsive interaction between different block components of the block copolymer becomes larger as the χN becomes larger. Therefore, when χN>10 (hereafter, referred to as “strong segregation limit”), there is a strong tendency for the phase separation to occur between different blocks in the block copolymer. At the strong segregation limit, the period of the block copolymer is approximately N^(2/3)χ^(1/6). That is, the period of the block copolymer is in proportion to the polymerization degree N which correlates with the molecular weight Mn and molecular weight ratio between different blocks. Therefore, by adjusting the composition and the total molecular weight of the block copolymer to be used, the period of the block copolymer can be adjusted.

<<Resin Component (N)>>

The brush composition according to a first aspect of the present invention includes a resin component (N), the resin component (N) containing a hydrophobic structural unit (Nx) and a hydrophilic structural unit (Ny), the amount of the structural unit (Ny) within the resin component (N) being 5 mol % or less.

The hydrophobic structural unit (Nx) (also referred to as “hydrophobic polymer block (Nx)”; hereafter, referred to simply as “block (Nx)”) is a block constituted of a polymer (hydrophobic polymer) obtained by polymerizing a monomer which exhibits relatively low affinity for water as compared to a monomer which provides a structural unit of the hydrophilic polymer block (b21) constituting the block copolymer. The structural unit of the block (Nx) and the structural unit of the block (11) may have the same structure, or different structures. Since the adhesion of the substrate to the layer containing a block copolymer via the brush layer becomes strong, the structural unit of the block (Nx) and the structural unit of the block (b11) preferably have the same structure.

The hydrophilic polymer block (Ny) (also referred to as “hydrophilic polymer block (Ny)”; hereafter, referred to simply as “block (Ny)”) is a block constituted of a polymer (hydrophilic polymer) obtained by polymerizing a monomer which exhibits relatively low affinity for water as compared to a monomer which provides a structural unit of the hydrophobic polymer block (b11) constituting the block copolymer. The structural unit of the block (Ny) and the structural unit of the block (b21) may have the same structure, or different structures.

Examples of the block (Nx) include a block in which structural units derived from styrene or a styrene derivative are repeatedly bonded.

Examples of the block (Ny) include a block in which structural units derived from an (α-substituted) acrylate ester are repeatedly bonded; a block in which structural units derived from an (α-substituted) acrylic acid are repeatedly bonded; a block in which structural units derived from siloxane or a derivative thereof are repeatedly bonded; a block in which structural units derived from an alkyleneoxide are repeatedly bonded; and a block in which silsesquioxane structure-containing structural units are repeatedly bonded.

Styrene or styrene derivative, the (α-substituted) acrylate ester, the (α-substituted) acrylic acid, siloxane or derivative thereof, the alkyleneoxide and the monomer which provides a silsesquioxane structure-containing structural unit for the block (Nx) and the block (Ny) are the same as defined for the examples of compounds described for the block (b11) and the block (b21).

In the present invention, the amount of the structural unit (Ny) within the resin component (N) is 5 mol % or less. The amount of the structural unit (Ny) is preferably 4 mol % or less, and more preferably 3 mol % or less.

In the resin component (N), the amount of the structural unit (Ny) is preferably 0.1 mol % or more, ore preferably 0.5 mol % or more, and most preferably 0.7 mol % or more.

The above upper limits and lower limits can be arbitrarily combined.

In the brush composition of the present invention, by virtue of the specific amount of the structural unit (Ny), when a brush layer is formed using the brush composition of the present invention, it is considered that the surface of the brush layer can be controlled to a highly hydrophobic state.

Structural Unit (Nx)

In the present invention, the structural unit (Nx) is a hydrophobic structural unit, and specifically, a structural unit containing a styrene skeleton which may have a substituent is preferable.

A styrene skeleton having a substituent refers to styrene in which the hydrogen atom on the α-position is substituted and/or part or all of the hydrogen atoms on the benzene ring are substituted with a substituent.

Examples of the substituent for the structural unit (Nx) include a halogen atom, or a linear, branched or cyclic hydrocarbon group of 1 to 20 carbon atoms optionally containing an oxygen atom, a halogen atom or a silicon atom, or a combination of the linear, branched or cyclic hydrocarbon group.

Examples of the halogen atom as the substituent for the structural unit (Nx) include a fluorine atom, chlorine atom, bromine atom and iodine atom, and a fluorine atom, a chlorine atom or a bromine atom is preferable.

The hydrocarbon group as the substituent for the structural unit (Nx) has 1 to 20 carbon atoms.

In addition, the hydrocarbon group is a linear, branched or cyclic hydrocarbon group optionally containing an oxygen atom, a halogen atom or a silicon atom, or a combination of the linear, branched or cyclic hydrocarbon group.

Examples of the hydrocarbon group include a linear, branched or cyclic alkyl group, or an aryl group.

The alkyl group as the hydrocarbon group preferably has 1 to 10 carbon atoms, more preferably 1 to 8 carbon atoms, and still more preferably 1 to 6 carbon atoms.

The alkyl group may be a partially or fully halogenated alkyl group (halogenated alkyl group), or an alkyl group in which a carbon atom constituting the alkyl group has been replaced by a silicon atom or an oxygen atom, such as an alkylsilyl group, an alkylsilyloxy group or an alkoxy group.

The “partially halogenated alkyl group” refers to an alkyl group in which part of the hydrogen atoms bonded to the alkyl group are substituted with halogen atom(s) and the “fully halogenated alkyl group” refers to an alkyl group in which all of the hydrogen atoms bonded the alkyl group are substituted with halogen atoms. Examples of the halogen atom include a fluorine atom, chlorine atom, bromine atom and iodine atom, a fluorine atom, a chlorine atom or a bromine atom is preferable, and a fluorine atom is more preferable (that is, a fluorinated alkyl group is preferable).

As the alkylsilyl group, a trialkylsilyl group or a trialkylsilylalkyl group is preferable, and preferable examples thereof include a trimethylsilyl group, a trimethylsilylmethyl group, a trimethylsilylethyl group and a trimethylsilyl-n-propyl group.

As the alkylsilyloxy group, a trialkylsilyloxy group or a trialkylsilyloxyalkyl group is preferable, and preferable examples thereof include a trimethylsilyloxy group, a trimethylsilyloxymethyl group, a trimethylsilyloxyethyl group and a trimethylsilyloxy-n-propyl group.

The alkoxy group preferably has 1 to 10 carbon atoms, more preferably 1 to 8 carbon atoms, and still more preferably 1 to 6 carbon atoms.

The aryl group as the hydrocarbon group has 4 to 20 carbon atoms, preferably 4 to 10 carbon atom, and more preferably 6 to 10 carbon atoms.

Preferable examples of the structural unit (Nx) include a structural unit represented by general formula (Nx-1) shown below.

In the formula, R represents a hydrogen atom, an alkyl group of 1 to 5 carbon atoms or a halogenated alkyl group of 1 to 5 carbon atoms; R¹ represents a halogen atom, or a linear, branched or cyclic hydrocarbon group of 1 to 20 carbon atoms optionally containing an oxygen atom, a halogen atom or a silicon atom, or a combination of the linear, branched or cyclic hydrocarbon group; and n represents an integer of 0 to 5.

In formula (Nx-1), R represents a hydrogen atom, an alkyl group of 1 to 5 carbon atoms or a halogenated alkyl group of 1 to 5 carbon atoms.

As the alkyl group of 1 to 5 carbon atoms for R, a linear or branched alkyl group of 1 to 5 carbon atoms is preferable, and specific examples thereof include a methyl group, an ethyl group, an n-propyl group, an isopropyl group, an n-butyl group, an isobutyl group, a tert-butyl group, a pentyl group, an isopentyl group and a neopentyl group.

The halogenated alkyl group of 1 to 5 carbon atoms represented by R is a group in which part or all of the hydrogen atoms of the aforementioned alkyl group of 1 to 5 carbon atoms have been substituted with halogen atoms. Examples of the halogen atom include a fluorine atom, a chlorine atom, a bromine atom and an iodine atom, and a fluorine atom is particularly desirable.

As R, a hydrogen atom, an alkyl group of 1 to 5 carbon atoms or a fluorinated alkyl group of 1 to 5 carbon atoms is preferable, a hydrogen atom or an alkyl group of 1 to 5 carbon atoms is more preferable, a hydrogen atom or a methyl group is still more preferable, and a hydrogen atom is most preferable.

In formula (Nx-1), R¹ represents a halogen atom, or a linear, branched or cyclic hydrocarbon group of 1 to 20 carbon atoms optionally containing an oxygen atom, a halogen atom or a silicon atom, or a combination of the linear, branched or cyclic hydrocarbon group.

In formula (Nx-1), R¹ is the same as defined for the substituent for the aforementioned structural unit (Nx) (a halogen atom, or a linear, branched or cyclic hydrocarbon group of 1 to 20 carbon atoms optionally containing an oxygen atom, a halogen atom or a silicon atom, or a combination of the linear, branched or cyclic hydrocarbon group).

Among these examples, as R¹, a linear, branched or cyclic hydrocarbon group of 1 to 20 carbon atoms optionally containing an oxygen atom, a halogen atom or a silicon atom, or a combination of the linear, branched or cyclic hydrocarbon group is preferable in that a layer containing a block copolymer to be formed on the brush layer can be satisfactorily phase-separated.

Among these, an alkyl group of 1 to 20 carbon atoms optionally containing an oxygen atom or a halogen atom is preferable, an alkyl group of 1 to 6 carbon atoms, a halogenated alkyl group of 1 to 6 carbon atoms or an alkoxy group of 1 to 6 carbon atoms is more preferable, and an alkyl group of 1 to 6 carbon atoms is most preferable.

The alkyl group for R¹ preferably has 1 to 6 carbon atoms, more preferably 3 to 6 carbon atoms, still more preferably 3 or 4 carbon atoms, and most preferably 4 carbon atoms. As the alkyl group for a linear alkyl group or a branched alkyl group is preferable, and preferable examples thereof include a methyl group, an ethyl group, an n-propyl group, an isopropyl group, an n-butyl group, an isobutyl group and a tert-butyl group, more preferably an n-propyl group, an isopropyl group, an n-butyl group, an isobutyl group or a tert-butyl group, still more preferably an n-butyl group, an isobutyl group or a tert-butyl group, and most preferably a tert-butyl group.

Examples of the halogenated alkyl group for R¹ include a group in which part or all of the hydrogen atoms of the alkyl group for R¹ have been substituted with halogen. As the halogen atom, a fluorine atom is most preferable. The halogenated alkyl group for R¹ preferably has 1 to 6 carbon atoms, more preferably 3 to 6 carbon atoms, and still more preferably 3 or 4 carbon atoms.

The alkoxy group for R¹ preferably has 1 to 6 carbon atoms, more preferably 1 to 4 carbon atoms, and most preferably 2 carbon atoms. As the alkoxy group for R¹, a linear alkoxy group or a branched alkoxy group is preferable, and preferable examples thereof include a methoxy group, an ethoxy group, an isopropoxy group and a t-butoxy group, and an ethoxy group is most preferable.

In formula (Nx-1), n represents an integer of 0 to 5, preferably an integer of 0 to 3, more preferably an integer of 0 to 2, still more preferably 0 or 1, and most preferably 0.

In formula (Nx-1), the bonding position of R¹ on the benzene ring is preferably the para position in that the phase-separation performance of the layer containing a block copolymer is further enhanced.

Specific examples of the structural unit (Nx) are shown below. In the formula, R^(α) represents a hydrogen atom or a methyl group.

As the structural unit (Nx), one kind of structural unit may be used alone, or two or more kinds of structural units may be used in combination.

As the structural unit (Nx), at least one member selected from the group consisting of structural units represented by chemical formulae (Nx-1-1) to (Nx-1-22) is preferable, at least one member selected from the group consisting of structural units represented by chemical formulae (Nx-1-1) to (Nx-1-14) is more preferable, at least one member selected from the group consisting of structural units represented by chemical formulae (Nx-1-1) to (Nx-1-11) is still more preferable, at least one member selected from the group consisting of structural units represented by chemical formulae (Nx-1-1) to (Nx-1-6) and (Nx-1-11) is still more preferable, and at least one member selected from the group consisting of structural units represented by chemical formulae (Nx-1-1) to (Nx-1-3) and (Nx-1-11) is most preferable.

In the component (N), the amount of the structural unit (Nx) based on the combined total of all structural units constituting the component (N) is preferably 95 mol % or more, more preferably 96 mol % or more, and still more preferably 97 mol % or more.

When the amount of the structural unit (Nx) is at least as large as the lower limit of the above-mentioned range, the surface of the brush layer becomes more stable, and the layer containing a block copolymer to be formed on the brush layer can be satisfactorily phase-separated.

Structural Unit (Ny)

In the present invention, the structural unit (Ny) is a hydrophilic group.

The structural unit (Ny) is preferably a structural derived from acrylic acid or an ester thereof which may have the hydrogen atom bonded to the carbon atom on the α-position substituted with a substituent.

Preferable examples of the structural unit (Ny) include a structural unit represented by general formula (Ny-1) shown below.

In the formula, R represents a hydrogen atom, an alkyl group of 1 to 5 carbon atoms or a halogenated alkyl group of 1 to 5 carbon atoms; and R² represents a linear or branched hydroxyalkyl group having 1 to 20 carbon atoms.

In formula (Ny-1), R represents a hydrogen atom, an alkyl group of 1 to 5 carbon atoms or a halogenated alkyl group of 1 to 5 carbon atoms. In formula (Ny-1), R is the same as defined for R in formula (Nx-1) above.

As R, a hydrogen atom, an alkyl group of 1 to 5 carbon atoms or a fluorinated alkyl group of 1 to 5 carbon atoms is preferable, a hydrogen atom or an alkyl group of 1 to 5 carbon atoms is more preferable, a hydrogen atom or a methyl group is still more preferable, and a hydrogen atom is most preferable.

In formula (Ny-1), R² represents a linear or branched alkyl group of 1 to 20 carbon atoms or a linear or branched hydroxyalkyl group of 1 to 20 carbon atoms.

The hydroxyalkyl group for R² is an alkyl group having 1 to 20 carbon atoms, preferably 1 to 10 carbon atoms, more preferably 1 to 8 carbon atoms, still more preferably 1 to 6 carbon atoms, and most preferably 1 to 4 carbon atoms, in which part or all of the hydrogen atoms of the alkyl group has been substituted with a hydroxy group. The number of the hydroxy group(s) is preferably 1 to 3, and more preferably 1 or 2.

The hydroxyalkyl group for R² may be linear or branched.

As the structural unit (Ny-1), a structural unit represented by general formula (Ny-1-1) shown below is preferable.

In the formula, R represents a hydrogen atom, an alkyl group of 1 to 5 carbon atoms or a halogenated alkyl group of 1 to 5 carbon atoms; and Y¹ represents an alkyl group of 1 to 5 carbon atoms.

In general formula (Ny-1-1) R is the same as defined above. In general formula (Ny-1-1), Y¹ represents an alkyl group of 1 to 5 carbon atoms and is the same as defined for the alkyl group of 1 to 5 carbon atoms for R in the aforementioned formula (Nx-1). Among these, as Y¹, a methyl group or an ethyl group is preferable, and a methyl group is more preferable.

Specific examples of the structural unit (Ny) are shown below. In the formula, R^(α) represents a hydrogen atom or a methyl group.

As the structural unit (Ny) contained in the component (N), 1 kind of structural unit may be used, or 2 or more kinds of structural units may be used in combination.

As the structural unit (Ny), at least one member selected from the group consisting of structural units represented by chemical formulae (Ny-1-1) to (Ny-1-3) is preferable, and a structural unit represented by chemical formula (Ny-1-1) is most preferable.

In the component (N), the amount of the structural unit (Ny) is less than 5 mol %. The amount of the structural unit (Ny) is preferably 4 mol % or less, and more preferably 3 mol % or less.

In the brush composition of the present invention, by virtue of the specific amount of the structural unit (Ny), when a brush layer is formed using the brush composition of the present invention, it is considered that the surface of the brush layer can be controlled to a highly hydrophobic state.

Optional Structural Unit

The component (N) may include, in addition to the structural unit (Nx) and the structural unit (Ny), an optional structural unit (structural unit (u3)), as long as the effects of the present invention are not impaired. Examples of the structural unit (u3) include structural units copolymerizable with the monomer which provides the structural unit (Nx).

When the component (N) includes the structural unit (u3), in the component (N), the amount of the structural unit (u3) based on the combined total of all structural units constituting the component (N) is preferably from more than 0 mol % to 25 mol %.

The weight average molecular weight (Mw) (the polystyrene equivalent value determined by gel permeation chromatography (GPC)) of the component (N) is not particularly limited, but is preferably 1,000 to 200,000, more preferably 1,500 to 200,000, and still more preferably 2,000 to 150,000.

When the weight average molecular weight is no more than the upper limit of the above preferable range, the component (A) satisfactorily dissolves in an organic solvent described later, and the coatability on a substrate becomes excellent. On the other hand, when the weight average molecular weight is at least as large as the lower limit of the above preferable range, the production stability of the polymeric compound becomes excellent, and the brush composition exhibits excellent coatability on a substrate.

The molecular weight dispersity (Mw/Mn) of the component (N) is not particularly limited, but is preferably 1.0 to 5.0, more preferably 1.0 to 3.0, and most preferably 1.0 to 2.5. Here, Mn is the number average molecular weight.

The component (N) can be obtained, for example, by a conventional radical polymerization or the like of the monomers corresponding with each of the structural units, using a radical polymerization initiator such as azobisisobutyronitrile (AIBN). Further, in the polymerization of the component (N), for example, an initiator such as CH₃—CH₂—CH(CH₃)—Li may be used.

Furthermore, in the polymerization of the component (N), for example, terminal modifier such as isobutylene sulfide may be used.

As the monomers for deriving the corresponding structural units, commercially available monomers may be used, or the monomers may be synthesized by a conventional method.

In the brush composition of the present invention, the amount of the component (N) can be appropriately adjusted depending on the thickness of the brush layer, and the like.

In the brush composition of the present invention, the amount of the component (N) based on the whole solid content is preferably 70% by weight or more, more preferably 90% by weight or more, and still more preferably 95% by weight or more.

<Optional Components>

The brush composition of the present invention may contain, in addition to the component (N), a component (optional component) other than the component (N).

Acid-Generator Component (B)

The brush composition of the present invention may further contain an acid-generator component (B) (hereafter, referred to as “component (B)”). The component (B) generates acid by heat or exposure. The component (B) itself does not need to exhibit acidity, may be any compound which is decomposed by heat or light and functions as an acid.

As the component (B), there is no particular limitation, and any of the known acid generator components used in chemically amplified resist compositions conventionally used in photolithography can be used.

Examples of the acid-generator component include a thermal acid generator that generates acid by heating, and a photoacid generator that generates acid upon exposure. Examples of these acid generators are numerous, and include onium salt acid generators such as iodonium salts and sulfonium salts; oxime sulfonate acid generators; diazomethane acid generators such as bisalkyl or bisaryl sulfonyl diazomethanes and poly(bis-sulfonyl)diazomethanes; nitrobenzylsulfonate acid generators; iminosulfonate acid generators; and disulfone acid generators.

A “thermal acid generator which generates acid by heating” refers to a component which generates acid upon heating preferably at 200° C. or lower. When the heating temperature is 200° C. or lower, generation of acid may be reliably controlled. Preferably, a component that generates acid by heating at 50 to 150° C. is used. When the preferable heating temperature is 50° C. or higher, the stability of the acid-generator component in the brush composition becomes satisfactory.

As the onium salt acid generator for the component (B), those in which have at least one anion group selected from a sulfonate anion, a carboxylate anion, a sulfonylimide anion, a bis(alkylsulfonyl)imide anion, a tris(alkylsulfonyl)methide anion and a fluoroantimonic acid ion as the anion moiety is preferable.

Further, as the cation moiety of an onium salt acid generator for the component (B), a cation moiety represented by general formula (b-c1) or (b-c2) shown below is preferable.

In the formulae, R¹″ to R³″, R⁵″ and R⁶″ each independently represents an aryl group which may have a substituent, an alkyl group which may have a substituent or an alkenyl group which may have a substituent, provided that, in formula (b-c1), two of R¹″ to R³″ may be mutually bonded to form a ring with the sulfur atom; and

In formula (b-c1), R¹″ to R³″ each independently represents an aryl group which may have a substituent or an alkyl group which may have a substituent. Two of R¹″ to R³″ may be mutually bonded to form a ring with the sulfur atom.

Examples of the aryl group for R¹″ to R³″ include an unsubstituted aryl group of 6 to 20 carbon atoms; a substituted aryl group in which part or all of the hydrogen atoms of the aforementioned unsubstituted aryl group has been substituted with an alkyl group, an alkoxy group, a halogen atom, a hydroxy group, an oxo group (═O), an aryl group, an alkoxyalkyloxy group, an alkoxycarbonylalkyloxy group, —C(═O)—O—R⁶′, —O—C(═O)—R⁷′ or —O—R⁸′. Each of R⁶′, R⁷′ and R⁸′ independently represents a linear or branched saturated hydrocarbon group of 1 to 25 atoms, a cyclic saturated hydrocarbon group of 3 to 20 carbon atoms or a linear or branched, aliphatic unsaturated hydrocarbon group of 2 to 5 carbon atoms.

The unsubstituted aryl group for R¹″ to R³″ is preferably an aryl group having 6 to 10 carbon atoms because it can be synthesized at a low cost. Specific examples thereof include a phenyl group and a naphthyl group.

The alkyl group as the substituent for the substituted aryl group represented by R¹″ to R³″ is preferably an alkyl group having 1 to 5 carbon atoms, and more preferably a methyl group, an ethyl group, a propyl group, an n-butyl group, or a tert-butyl group.

The alkoxy group as the substituent for the substituted aryl group is preferably an alkoxy group having 1 to 5 carbon atoms, and more preferably a methoxy group, an ethoxy group, an n-propoxy group, an iso-propoxy group, an n-butoxy group or a tert-butoxy group.

The halogen atom as the substituent for the substituted aryl group is preferably a fluorine atom.

As the aryl group as the substituent for the substituted aryl group, the same aryl groups as those described for R¹″ to R³″ can be mentioned.

Examples of alkoxyalkyloxy groups as the substituent for the substituted aryl group include groups represented by a general formula shown below: —O—C(R⁴⁷)(R⁴⁸)—O—R⁴⁹

In the formula, R⁴⁷ and R⁴⁸ each independently represents a hydrogen atom or a linear or branched alkyl group; and R⁴⁹ represents an alkyl group.

The alkyl group for R⁴⁷ and R⁴⁸ preferably has 1 to 5 carbon atoms, and may be either linear or branched. As the alkyl group, an ethyl group or a methyl group is preferable, and a methyl group is most preferable.

It is preferable that at least one of R⁴⁷ and R⁴⁸ be a hydrogen atom. It is particularly desirable that at least one of R⁴⁷ and R⁴⁸ be a hydrogen atom, and the other be a hydrogen atom or a methyl group.

The alkyl group for R⁴⁹ preferably has 1 to 15 carbon atoms, and may be linear, branched or cyclic.

The linear or branched alkyl group for R⁴⁹ preferably has 1 to 5 carbon atoms. Examples thereof include a methyl group, an ethyl group, a propyl group, an n-butyl group and a tert-butyl group.

The cyclic alkyl group for R⁴⁹ preferably has 4 to 15 carbon atoms, more preferably 4 to 12, and most preferably 5 to 10. Specific examples thereof include groups in which one or more hydrogen atoms have been removed from a monocycloalkane or a polycycloalkane such as a bicycloalkane, tricycloalkane or tetracycloalkane, and which may or may not be substituted with an alkyl group of 1 to 5 carbon atoms, a fluorine atom or a fluorinated alkyl group. Examples of the monocycloalkane include cyclopentane and cyclohexane. Examples of polycycloalkanes include adamantane, norbornane, isobornane, tricyclodecane and tetracyclododecane. Among these, a group in which one or more hydrogen atoms have been removed from adamantane is preferable.

Examples of the alkoxycarbonylalkyloxy group as the substituent for the substituted aryl group include groups represented by a general formula shown below: —O—R⁵⁰—C(═O)—O—R⁵⁶

In the formula, R⁵⁰ represents a linear or branched alkylene group, and R⁵⁶ represents a tertiary alkyl group.

The linear or branched alkylene group for R⁵⁰ preferably has 1 to 5 carbon atoms, and examples thereof include a methylene group, an ethylene group, a trimethylene group, a tetramethylene group and a 1,1-dimethylethylene group.

Examples of the tertiary alkyl group for R⁵⁶ include a 2-methyl-2-adamantyl group, a 2-ethyl-2-adamantyl group, a 1-methyl-1-cyclopentyl group, a 1-ethyl-1-cyclopentyl group, a 1-methyl-1-cyclohexyl group, a 1-ethyl-1-cyclohexyl group, a 1-(1-adamantyl)-1-methylethyl group, a 1-(1-adamantyl)-1-methylpropyl group, a 1-(1-adamantyl)-1-methylbutyl group, a 1-(1-adamantyl)-1-methylpentyl group, a 1-(1-cyclopentyl)-1-methylethyl group, a 1-(1-cyclopentyl)-1-methylpropyl group, a 1-(1-cyclopentyl)-1-methylbutyl group, a 1-(1-cyclopentyl)-1-methylpentyl group, a 1-(1-cyclohexyl)-1-methylethyl group, a 1-(1-cyclohexyl)-1-methylpropyl group, a 1-(1-cyclohexyl)-1-methylbutyl group, a 1-(1-cyclohexyl)-1-methylpentyl group, a tert-butyl group, a tert-pentyl group and a tert-hexyl group.

Further, a group in which R⁵⁶ in the group represented by the aforementioned general formula: —O—R⁵⁰—C(═O)—O—R⁵⁶ has been substituted with R⁵⁶′ can also be mentioned. R⁵⁶′ represents a hydrogen atom, an alkyl group, a fluorinated alkyl group or an aliphatic cyclic group which may contain a hetero atom.

The alkyl group for R⁵⁶′ is the same as defined for the alkyl group for the aforementioned R⁴⁹.

Examples of the fluorinated alkyl group for R⁵⁶′ include groups in which part or all of the hydrogen atoms within the alkyl group for R⁴⁹ has been substituted with a fluorine atom.

Examples of the aliphatic cyclic group for R⁵⁶′ which may contain a hetero atom include an aliphatic cyclic group which does not contain a hetero atom, an aliphatic cyclic group containing a hetero atom in the ring structure, and an aliphatic cyclic group in which a hydrogen atom has been substituted with a hetero atom.

As an aliphatic cyclic group for R⁵⁶′ which does not contain a hetero atom, a group in which one or more hydrogen atoms have been removed from a monocycloalkane or a polycycloalkane such as a bicycloalkane, a tricycloalkane or a tetracycloalkane can be mentioned. Examples of the monocycloalkane include cyclopentane and cyclohexane. Examples of polycycloalkanes include adamantane, norbornane, isobornane, tricyclodecane and tetracyclododecane. Among these, a group in which one or more hydrogen atoms have been removed from adamantane is preferable.

Specific examples of the aliphatic cyclic group for R⁵⁶′ containing a hetero atom in the ring structure include aliphatic cyclic groups represented by formulae (L1) to (L6) and (S1) to (S4) below.

In the formula, Q″ represents an alkylene group of 1 to 5 carbon atoms, —O—, —S—, —O—R⁹⁴— or —S—R⁹⁵— (wherein each of R⁹⁴ and R⁹⁵ independently represents an alkylene group of 1 to 5 carbon atoms); and m represents 0 or 1.

In the above formulae, the linear or branched alkylene group for Q″, R⁹⁴ and R⁹⁵ preferably has 1 to 5 carbon atoms, and examples thereof include a methylene group, an ethylene group, a trimethylene group, a tetramethylene group and a 1,1-dimethylethylene group.

In these aliphatic cyclic groups, part of the hydrogen atoms bonded to the carbon atoms constituting the ring structure may be substituted with a substituent. Examples of substituents include an alkyl group, an alkoxy group, a halogen atom, a halogenated alkyl group, a hydroxyl group and an oxygen atom (═O).

As the alkyl group, an alkyl group of 1 to 5 carbon atoms is preferable, and a methyl group, an ethyl group, a propyl group, an n-butyl group or a tert-butyl group is particularly desirable.

The alkoxy group as the substituent is preferably an alkoxy group having 1 to 5 carbon atoms, more preferably a methoxy group, ethoxy group, n-propoxy group, iso-propoxy group, n-butoxy group or tert-butoxy group, and most preferably a methoxy group or an ethoxy group.

Examples of the halogen atom for the substituent include a fluorine atom, a chlorine atom, a bromine atom and an iodine atom, and a fluorine atom is preferable.

As the aliphatic cyclic group for R⁵⁶′ in which a hydrogen atom has been substituted with a hetero atom, an aliphatic cyclic group in which a hydrogen atom has been substituted with an oxygen atom (═O) can be mentioned.

In formulae —C(═O)—O—R⁶′, —O—C(═O)—R⁷′ and —O—R⁸′, R⁶′, R⁷′ and R⁸′ each independently represents a linear or branched saturated hydrocarbon group of 1 to 25 atoms, a cyclic saturated hydrocarbon group of 3 to 20 carbon atoms or a linear or branched, aliphatic unsaturated hydrocarbon group of 2 to 5 carbon atoms.

The linear or branched, saturated hydrocarbon group preferably has 1 to 25 carbon atoms, more preferably 1 to 15, and still more preferably 4 to 10.

Examples of the linear, saturated hydrocarbon group include a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group, a hexyl group, a heptyl group, an octyl group, a nonyl group and a decyl group.

Examples of the branched, saturated hydrocarbon group include a 1-methyl ethyl group, a 1-methylpropyl group, a 2-methylpropyl group, a 1-methylbutyl group, a 2-methylbutyl group, a 3-methylbutyl group, a 1-ethylbutyl group, a 2-ethylbutyl group, a 1-methylpentyl group, a 2-methylpentyl group, a 3-methylpentyl group and a 4-methylpentyl group, but excluding tertiary alkyl groups.

The linear or branched, saturated hydrocarbon group may have a substituent. Examples of the substituent include an alkoxy group, a halogen atom, a halogenated alkyl group, a hydroxyl group, an oxygen atom (═O), a cyano group and a carboxy group.

The alkoxy group as the substituent for the linear or branched saturated hydrocarbon group is preferably an alkoxy group having 1 to 5 carbon atoms, more preferably a methoxy group, an ethoxy group, an n-propoxy group, an iso-propoxy group, an n-butoxy group or a tert-butoxy group, and most preferably a methoxy group or an ethoxy group.

Examples of the halogen atom as the substituent for the linear or branched, saturated alkyl group include a fluorine atom, a chlorine atom, a bromine atom and an iodine atom, and a fluorine atom is preferable.

Example of the halogenated alkyl group as the substituent for the linear or branched, saturated hydrocarbon group includes a group in which part or all of the hydrogen atoms within the aforementioned linear or branched, saturated hydrocarbon group have been substituted with the aforementioned halogen atoms.

The cyclic saturated hydrocarbon group of 3 to 20 carbon atoms for R⁶′, R⁷′ and R⁸′ may be either a polycyclic group or a monocyclic group, and examples thereof include groups in which one hydrogen atom has been removed from a monocycloalkane, and groups in which one hydrogen atom has been removed from a polycycloalkane (e.g., a bicycloalkane, a tricycloalkane or a tetracycloalkane). More specific examples include groups in which one hydrogen atom has been removed from a monocycloalkane such as cyclopentane, cyclohexane, cycloheptane or cyclooctane; and groups in which one or more hydrogen atoms have been removed from a polycycloalkane such as adamantane, norbornane, isobornane, tricyclodecane or tetracyclododecane.

The cyclic, saturated hydrocarbon group may have a substituent. For example, part of the carbon atoms constituting the ring within the cyclic alkyl group may be substituted with a hetero atom, or a hydrogen atom bonded to the ring within the cyclic alkyl group may be substituted with a substituent.

In the former example, a heterocycloalkane in which part of the carbon atoms constituting the ring within the aforementioned monocycloalkane or polycycloalkane has been substituted with a hetero atom such as an oxygen atom, a sulfur atom or a nitrogen atom, and one hydrogen atom has been removed therefrom, can be used. Further, the ring may contain an ester bond (—C(═O)—O—). More specific examples include a lactone-containing monocyclic group, such as a group in which one hydrogen atom has been removed from γ-butyrolactone; and a lactone-containing polycyclic group, such as a group in which one hydrogen atom has been removed from a bicycloalkane, tricycloalkane or tetracycloalkane containing a lactone ring.

In the latter example, as the substituent, the same substituent groups as those for the aforementioned linear or branched alkyl group, or an alkyl group of 1 to 5 carbon atoms can be used.

Alternatively, R⁶′, R⁷′ and R⁸′ may be a combination of a linear or branched alkyl group and a cyclic group.

Examples of the combination of a linear or branched alkyl group with a cyclic alkyl group include groups in which a cyclic alkyl group as a substituent is bonded to a linear or branched alkyl group, and groups in which a linear or branched alkyl group as a substituent is bonded to a cyclic alkyl group.

Examples of the linear aliphatic unsaturated hydrocarbon group for R⁶′, R⁷′ and R⁸′ include a vinyl group, a propenyl group (an allyl group) and a butynyl group.

Examples of the branched aliphatic unsaturated hydrocarbon group for R⁶′, R⁷′ and R⁸′ include a 1-methylpropenyl group and a 2-methylpropenyl group.

The aforementioned linear or branched, aliphatic unsaturated hydrocarbon group may have a substituent.

Examples of substituents include the same substituents as those which the aforementioned linear or branched alkyl group may have.

Among the aforementioned examples, as R⁶′, R⁷′ and R⁸′ a linear or branched, saturated hydrocarbon group of 1 to 15 carbon atoms or a cyclic saturated hydrocarbon group of 3 to 20 carbon atoms is preferable.

Examples of the alkyl group for R¹″ to R³″ include linear, branched or cyclic alkyl groups of 1 to 10 carbon atoms. Among these, alkyl groups of 1 to 5 carbon atoms are preferable as the resolution becomes excellent. Specific examples thereof include a methyl group, an ethyl group, an n-propyl group, an isopropyl group, an n-butyl group, an isobutyl group, an n-pentyl group, a cyclopentyl group, a hexyl group, a cyclohexyl group, a nonyl group, and a decyl group, and a methyl group is most preferable because it is excellent in resolution and can be synthesized at a low cost.

The alkyl group for R¹″ to R³″ may have part or all of the hydrogen atoms substituted with an alkoxy group, a halogen atom, a hydroxy group, an oxo group (═O), an aryl group, an alkoxyalkyloxy group, alkoxycarbonylalkyloxy group, —C(═O)—O—R⁶′, —O—C(═O)—R⁷′ and —O—R⁸′. The alkoxy group, the halogen atom, the aryl group, the alkoxyalkyloxy group, the alkoxycarbonylalkyloxy group, —C(═O)—O—R⁶′, —O—C(═O)—R⁷′ and —O—R⁸′ are the same as defined for the substituent for the aryl group represented by R¹″ to R³″.

The alkenyl group for R¹″ to R³″ preferably has 2 to 10 carbon atoms, more preferably 2 to 5, and still more preferably 2 to 4. Specific examples thereof include a vinyl group, a propenyl group (an allyl group), a butynyl group, a 1-methylpropenyl group and a 2-methylpropenyl group.

When two of R¹″ to R³″ are bonded to each other to form a ring with the sulfur atom, it is preferable that the two of R¹″ to R³″ form a 3 to 10-membered ring including the sulfur atom, and it is particularly desirable that the two of to R³″ form a 5 to 7-membered ring including the sulfur atom.

Preferable examples of the cation moiety of the compound represented by the aforementioned formula (b-c1) are shown below.

In the formulae, g1, g2 and g3 represent recurring numbers, wherein g1 is an integer of 1 to 5, g2 is an integer of 0 to 20, and g3 is an integer of 0 to 20.

In formula (ca-1-47), R^(d) represents a substituent. Examples of the substituent include those described above in the explanation of the aforementioned substituted aryl group (an alkyl group, an alkoxy group, an alkoxyalkyloxy group, an alkoxycarbonylalkyloxy group, a halogen atom, a hydroxy group, an oxo group (═O), an aryl group, —C(═O)—O—R⁶″, —O—C(═O)—R⁷″, and —O—R⁸″).

In formula (b-c2), R⁵″ and R⁶″ each independently represents an aryl group which may have a substituent or an alkyl group which may have a substituent.

As the aryl group for R⁵″ and R⁶″, the same aryl groups as those described above for R¹″ to R³″ can be used. The alkyl group for R⁵″ and R⁶″ is the same as defined for the alkyl group for R¹″ to R³″. The alkenyl group for R⁵″ and R⁶″ is the same as defined for the alkenyl group for R¹″ to R³″.

Specific examples of the cation moiety of the compound represented by general formula (b-c2) include diphenyliodonium and bis(4-tert-butylphenyl)iodonium.

In the present description, an oximesulfonate acid generator is a compound having at least one group represented by general formula (B-1) shown below, and has a feature of generating acid by irradiation. In general, such oximesulfonate acid generators are widely used for a chemically amplified resist composition, and can be appropriately selected.

In formula (B-1), each of R³¹ and R³² independently represents an organic group.

The organic group for R³¹ and R³² refers to a group containing a carbon atom, and may include atoms other than carbon atoms (e.g., a hydrogen atom, an oxygen atom, a nitrogen atom, a sulfur atom, a halogen atom (such as a fluorine atom and a chlorine atom) and the like).

As the organic group for R³¹, a linear, branched, or cyclic alkyl group or aryl group is preferable. The alkyl group or the aryl group may have a substituent. The substituent is not particularly limited, and examples thereof include a fluorine atom and a linear, branched, or cyclic alkyl group having 1 to 6 carbon atoms. The alkyl group or the aryl group “has a substituent” means that part or all of the hydrogen atoms of the alkyl group or the aryl group is substituted with a substituent.

The alkyl group preferably has 1 to 20 carbon atoms, more preferably 1 to 10 carbon atoms, still more preferably 1 to 8 carbon atoms, still more preferably 1 to 6 carbon atoms, and most preferably 1 to 4 carbon atoms. As the alkyl group, a partially or completely halogenated alkyl group (hereinafter, sometimes referred to as a “halogenated alkyl group”) is particularly desirable. The “partially halogenated alkyl group” refers to an alkyl group in which part of the hydrogen atoms are substituted with halogen atoms and the “completely halogenated alkyl group” refers to an alkyl group in which all of the hydrogen atoms are substituted with halogen atoms. Examples of halogen atoms include fluorine atoms, chlorine atoms, bromine atoms and iodine atoms, and fluorine atoms are particularly desirable. In other words, the halogenated alkyl group is preferably a fluorinated alkyl group.

The aryl group preferably has 4 to 20 carbon atoms, more preferably 4 to 10 carbon atoms, and most preferably 6 to 10 carbon atoms. As the aryl group, partially or completely halogenated aryl group is particularly desirable. The “partially halogenated aryl group” refers to an aryl group in which some of the hydrogen atoms are substituted with halogen atoms and the “completely halogenated aryl group” refers to an aryl group in which all of hydrogen atoms are substituted with halogen atoms.

As R³¹, an alkyl group of 1 to 4 carbon atoms which has no substituent or a fluorinated alkyl group of 1 to 4 carbon atoms is particularly desirable.

As the organic group for R³², a linear, branched, or cyclic alkyl group, aryl group, or cyano group is preferable. Examples of the alkyl group and the aryl group for R³² include the same alkyl groups and aryl groups as those described above for R³¹.

As R³², a cyano group, an alkyl group of 1 to 8 carbon atoms having no substituent or a fluorinated alkyl group of 1 to 8 carbon atoms is particularly desirable.

Preferred examples of the oxime sulfonate acid generator include compounds represented by general formula (B-2) or (B-3) shown below.

In formula (B-2), R³³ represents a cyano group, an alkyl group having no substituent or a halogenated alkyl group; R³⁴ represents a group containing an aryl group; provided that the alkyl group or the halogenated alkyl group for R³⁴ may be bonded with R³⁵ to form a ring; R³⁵ represents an alkyl group having no substituent or a halogenated alkyl group.

In the formula, R³⁶ represents a cyano group, an alkyl group having no substituent or a halogenated alkyl group; R³⁷ represents a divalent or trivalent aromatic hydrocarbon group; R³⁸ represents an alkyl group having no substituent or a halogenated alkyl group; and p″ represents 2 or 3.

In general formula (B-2), the alkyl group having no substituent or the halogenated alkyl group for R³³ preferably has 1 to 10 carbon atoms, more preferably 1 to 8 carbon atoms, and most preferably 1 to 6 carbon atoms.

As R³³, a halogenated alkyl group is preferable, and a fluorinated alkyl group is more preferable.

The fluorinated alkyl group for R³³ preferably has 50% or more of the hydrogen atoms thereof fluorinated, more preferably 70% or more, and most preferably 90% or more.

Examples of the group containing an aryl group for R³⁴ include groups in which one hydrogen atom has been removed from an aromatic hydrocarbon ring, such as a phenyl group, a biphenyl group, a fluorenyl group, a naphthyl group, an anthryl group, and a phenanthryl group, and heteroaryl groups in which some of the carbon atoms constituting the ring(s) of these groups are substituted with hetero atoms such as an oxygen atom, a sulfur atom, and a nitrogen atom. Of these, a fluorenyl group is preferable.

The group containing an aryl group for R³⁴ may have a substituent such as an alkyl group of 1 to 10 carbon atoms, a halogenated alkyl group, or an alkoxy group. The alkyl group and halogenated alkyl group as the substituent preferably has 1 to 8 carbon atoms, and more preferably 1 to 4 carbon atoms. Further, the halogenated alkyl group is preferably a fluorinated alkyl group.

The alkyl group having no substituent or the halogenated alkyl group for R³⁵ preferably has 1 to 10 carbon atoms, more preferably 1 to 8 carbon atoms, and most preferably 1 to 6 carbon atoms.

As R³⁵, a halogenated alkyl group is preferable, and a fluorinated alkyl group is more preferable.

In terms of enhancing the strength of the acid generated, the fluorinated alkyl group for R³⁵ preferably has 50% or more of the hydrogen atoms fluorinated, more preferably 70% or more, still more preferably 90% or more. A completely fluorinated alkyl group in which 100% of the hydrogen atoms are substituted with fluorine atoms is particularly desirable.

In general formula (B-3), as the alkyl group having no substituent and the halogenated alkyl group for R³⁶, the same alkyl group having no substituent and the halogenated alkyl group described above for R³³ can be used.

Examples of the divalent or trivalent aromatic hydrocarbon group for R³⁷ include groups in which one or two hydrogen atoms have been removed from the aryl group for R³⁴.

As the alkyl group having no substituent or the halogenated alkyl group for R³⁸, the same one as the alkyl group having no substituent or the halogenated alkyl group for R³⁵ can be used.

p″ is preferably 2.

Specific examples of suitable oxime sulfonate acid generators include α-(p-toluenesulfonyloxyimino)-benzyl cyanide, α-(p-chlorobenzenesulfonyloxyimino)-benzyl cyanide, α-(4-nitrobenzenesulfonyloxyimino)-benzyl cyanide, α-(4-nitro-2-trifluoromethylbenzenesulfonyloxyimino)-benzyl cyanide, α-(benzenesulfonyloxyimino)-4-chlorobenzyl cyanide, α-(benzenesulfonyloxyimino)-2,4-dichlorobenzyl cyanide, α-(benzenesulfonyloxyimino)-2,6-dichlorobenzyl cyanide, α-(benzenesulfonyloxyimino)-4-methoxybenzyl cyanide, α-(2-chlorobenzenesulfonyloxyimino)-4-methoxybenzyl cyanide, α-(benzenesulfonyloxyimino)-thien-2-yl acetonitrile, α-(4-dodecylbenzenesulfonyloxyimino)benzyl cyanide, α-└(p-toluenesulfonyloxyimino)-4-methoxyphenyl┘ acetonitrile, α-[(dodecylbenzenesulfonyloxyimino)-4-methoxyphenyl] acetonitrile, α-(tosyloxyimino)-4-thienyl cyanide, α-(methylsulfonyloxyimino)-1-cyclopentenyl acetonitrile, α-(methylsulfonyloxyimino)-1-cyclohexenyl acetonitrile, α-(methylsulfonyloxyimino)-1-cycloheptenyl acetonitrile, α-(methylsulfonyloxyimino)-1-cyclooctenyl acetonitrile, α-(trifluoromethylsulfonyloxyimino)-1-cyclopentenyl acetonitrile, α-(trifluoromethylsulfonyloxyimino)-cyclohexyl acetonitrile, α-(ethylsulfonyloxyimino)-ethyl acetonitrile, α-(propylsulfonyloxyimino)-propyl acetonitrile, α-(cyclohexylsulfonyloxyimino)-cyclopentyl acetonitrile, α-(cyclohexylsulfonyloxyimino)-cyclohexyl acetonitrile, α-(cyclohexylsulfonyloxyimino)-1-cyclopentenyl acetonitrile, α-(ethylsulfonyloxyimino)-1-cyclopentenyl acetonitrile, α-(isopropylsulfonyloxyimino)-1-cyclopentenyl acetonitrile, α-(n-butylsulfonyloxyimino)-1-cyclopentenyl acetonitrile, α-(ethylsulfonyloxyimino)-1-cyclohexenyl acetonitrile, α-(isopropylsulfonyloxyimino)-1-cyclohexenyl acetonitrile, α-(n-butylsulfonyloxyimino)-1-cyclohexenyl acetonitrile, α-(methylsulfonyloxyimino)-phenyl acetonitrile, α-(methylsulfonyloxyimino)-p-methoxyphenyl acetonitrile, α-(trifluoromethylsulfonyloxyimino)-phenyl acetonitrile, α-(trifluoromethylsulfonyloxyimino)-p-methoxyphenyl acetonitrile, α-(ethylsulfonyloxyimino)-p-methoxyphenyl acetonitrile, α-(propylsulfonyloxyimino)-p-methylphenyl acetonitrile, and α-(methylsulfonyloxyimino)-p-bromophenyl acetonitrile.

Further, oxime sulfonate acid generators disclosed in Japanese Unexamined Patent Application, First Publication No. Hei 9-208554 (Chemical Formulas 18 and 19 shown in paragraphs [0012] to [0014]) and oxime sulfonate acid generators disclosed in WO 2004/074242A2 (Examples 1 to 40 described at pages 65 to 85) may be preferably used.

Furthermore, as preferable examples, the following can be used.

Of the aforementioned diazomethane acid generators, specific examples of suitable bisalkyl or bisaryl sulfonyl diazomethanes include bis(isopropylsulfonyl)diazomethane, bis(p-toluenesulfonyl)diazomethane, bis(1,1-dimethylethylsulfonyl)diazomethane, bis(cyclohexylsulfonyl)diazomethane, and bis(2,4-dimethylphenylsulfonyl)diazomethane.

Further, diazomethane acid generators disclosed in Japanese Unexamined Patent Application, First Publication No. Hei 11-035551, Japanese Unexamined Patent Application, First Publication No. Hei 11-035552 and Japanese Unexamined Patent Application, First Publication No. Hei 11-035573 may be preferably used.

Furthermore, as examples of poly(bis-sulfonyl)diazomethanes, those disclosed in Japanese Unexamined Patent Application, First Publication No. Hei 11-322707, including 1,3-bis(phenylsulfonyldiazomethylsulfonyl)propane, 1,4-bis(phenylsulfonyldiazomethylsulfonyl)butane, 1,6-bis(phenylsulfonyldiazomethylsulfonyl)hexane, 1,10-bis(phenylsulfonyldiazomethylsulfonyl)decane, 1,2-bis(cyclohexylsulfonyldiazomethylsulfonyl)ethane, 1,3-bis(cyclohexylsulfonyldiazomethylsulfonyl)propane, 1,6-bis(cyclohexylsulfonyldiazomethylsulfonyl)hexane, and 1,10-bis(cyclohexylsulfonyldiazomethylsulfonyl)decane, may be given.

In the brush composition of the present invention, as the component (B), 1 kind of acid generator may be used, or 2 or more kinds of acid generators may be used in combination.

When the brush composition contains the component (B), the amount of the component (B) relative to 100 parts by weight of the component (N) is preferably within a range from 0.5 to 30 parts by weight, and more preferably from 1 to 20 parts by weight.

When the amount of the component (B) is within the above range, the effects of the present invention can be satisfactorily achieved.

If desired, other miscible additives can also be added to the brush composition of the present invention, as long as the effects of the present invention are not impaired. Examples of such miscible additives include additive resins for improving the performance of the brush layer, surfactants for improving the applicability, dissolution inhibitors, plasticizers, stabilizers, colorants, halation prevention agents, dyes, sensitizers, base amplifiers and basic compounds (e.g., nitrogen-containing compounds, such as imidazole).

Organic Solvent (S)

The brush composition according to the present invention can be produced by dissolving the raw materials including the component (N) and the component (B) and the like if desired, in an organic solvent (hereafter, referred to as “component (S)”).

The component (S) may be any organic solvent which can dissolve the respective components to give a uniform solution, and one or more kinds of any organic solvent can be appropriately selected from those which have been conventionally known as solvents for a film composition containing a resin as a main component.

Examples of the component (S) include lactones such as γ-butyrolactone; ketones such as acetone, methyl ethyl ketone, cyclohexanone, methyl-n-pentyl ketone, methyl isopentyl ketone, and 2-heptanone; polyhydric alcohols, such as ethylene glycol, diethylene glycol, propylene glycol and dipropylene glycol; compounds having an ester bond, such as ethylene glycol monoacetate, diethylene glycol monoacetate, propylene glycol monoacetate, and dipropylene glycol monoacetate; polyhydric alcohol derivatives including compounds having an ether bond, such as a monoalkylether (e.g., monomethylether, monoethylether, monopropylether or monobutylether) or monophenylether of any of these polyhydric alcohols or compounds having an ester bond (among these, propylene glycol monomethyl ether acetate (PGMEA) and propylene glycol monomethyl ether (PGME) are preferable); cyclic ethers such as dioxane; esters such as methyl lactate, ethyl lactate (EL), methyl acetate, ethyl acetate, butyl acetate, methyl pyruvate, ethyl pyruvate, methyl methoxypropionate, and ethyl ethoxypropionate; and aromatic organic solvents such as anisole, ethylbenzylether, cresylmethylether, diphenylether, dibenzylether, phenetole, butylphenylether, ethylbenzene, diethylbenzene, pentylbenzene, isopropylbenzene, toluene, xylene, cymene and mesitylene.

The component (S) can be used individually, or in combination as a mixed solvent.

Among these examples, as the component (S), propylene glycol monomethyl ether acetate (PGMEA), propylene glycol monomethyl ether (PGME), cyclohexanone and ethyl lactate (EL) are preferable.

Further, among the mixed solvents, a mixed solvent obtained by mixing PGMEA with a polar solvent is preferable. The mixing ratio (weight ratio) of the mixed solvent can be appropriately determined, taking into consideration the compatibility of the PGMEA with the polar solvent, but is preferably in the range of 1:9 to 9:1, more preferably from 2:8 to 8:2. For example, when EL is mixed as the polar solvent, the PGMEA:EL weight ratio is preferably from 1:9 to 9:1, and more preferably from 2:8 to 8:2. Alternatively, when PGME is mixed as the polar solvent, the PGMEA:PGME weight ratio is preferably from 1:9 to 9:1, more preferably from 2:8 to 8:2, and still more preferably 3:7 to 7:3. Alternatively, when PGME and cyclohexanone is mixed as the polar solvent, the PGMEA:(PGME+cyclohexanone) weight ratio is preferably from 1:9 to 9:1, more preferably from 2:8 to 8:2, and still more preferably 3:7 to 7:3.

Further, as the component (S), a mixed solvent of γ-butyrolactone with PGMEA, EL or the aforementioned mixed solvent of PGMEA with a polar solvent, is also preferable. The mixing ratio (former:latter) of such a mixed solvent is preferably from 70:30 to 95:5.

The amount of the component (S) is not particularly limited, and is appropriately adjusted to a concentration which enables coating of a coating solution to a substrate, depending on the thickness of the coating film. In general, the organic solvent is used in an amount such that the solid content of the brush composition becomes within the range from 0.1 to 20% by weight, and preferably from 0.2 to 15% by weight.

(Water Contact Angle on the Surface of the Brush Layer Formed on the Substrate)

A brush layer formed on a substrate using the brush composition according to the present invention preferably has a water contact angle of 80° or more, and more preferably 85° or more.

When the value of the contact angle is within the above preferable range, it is considered that the adhesion of the substrate to the layer containing a block copolymer via the brush layer becomes strong. As a result, it is considered that the phase-separation performance of the layer containing a block copolymer formed on the brush layer is improved.

The water contact angle is measured, for example, by the following steps.

Step (1): A PGMEA solution of component (N) is applied to a substrate, so as to form a brush layer having a film thickness of less than 10 nm.

Step (2): 2 μL of water is dropped onto the surface of the brush layer, and the contact angle (static contact angle) is measured by a contact angle meter.

The brush composition according to the present invention includes a resin component (N), the resin component (N) containing a hydrophobic structural unit (Nx) and a hydrophilic structural unit (Ny), the amount of the structural unit (Ny) within the resin component (N) being 5 mol % or less.

When the brush composition is used as a surface modifier for a substrate which is used for phase-separation of a layer containing a block copolymer formed on the substrate, the adhesion of the substrate to the layer containing a block copolymer via the brush layer formed of the brush composition becomes strong. It is presumed that, in this manner, the phase-separation performance of the block copolymer can be improved.

Further, with respect to the brush composition, since the surface state of the brush layer is stable, there is no need to select a neutral layer material which can obtain a brush layer having a surface free energy of a predetermined value each time, depending on the kind of the block copolymer used. Therefore, the brush composition can be conveniently used.

<Method of Producing Structure Containing Phase-Separated Structure>

A second aspect of the present invention is a method of producing a structure containing a phase-separated structure, the method including: a step of applying the brush composition of the first aspect to form a brush layer (hereafter, referred to as “step (i)”); a step of forming a layer containing a block copolymer on the brush layer (hereafter, referred to as “step (ii)”); and a step of phase-separating the layer containing the block copolymer (hereafter, referred to as “step (iii)”).

Hereinafter, the method of producing a structure containing a phase-separated structure will be specifically described with reference to FIG. 1. However, the present invention is not limited to these embodiments.

FIG. 1 shows an example of one embodiment of the method of forming a structure containing a phase-separated structure according to the present invention.

Firstly, the brush composition of the present invention is applied to a substrate 1, so as to form a brush layer 2 (FIG. 1 (I); step (i)).

Subsequently, to the brush layer 2 is applied a composition containing a block copolymer (hereafter, sometimes referred to as “BCP composition”), so as to form a layer 3 containing the block copolymer (FIG. 1 (II); step (ii)).

Next, heating is conducted to perform an annealing treatment, so as to phase-separate the layer 3 containing the block copolymer into a phase 3 a and a phase 3 b (FIG. 1 (III); step (iii)).

According to the production method of the present embodiment, that is, the production method including the steps (i) to (iii), a structure 3′ containing a phase-separated structure is formed on the substrate 1 having the brush layer 2 formed thereon.

[Step (i)]

In step (i), the brush composition is applied to a substrate 1, so as to form a brush layer 2.

By forming a brush layer 2 on the substrate 1, the hydrophilicity-hydrophobicity balance between the surface of the substrate 1 and the layer 3 containing the block copolymer can be obtained.

That is, by virtue of the resin component (N) contained in the brush composition used for the brush layer 2 having the hydrophilic structural unit (Ny) in an amount of 5 mol % or less, the adhesion between the substrate 1 and the hydrophobic polymer block (b11) within the layer 3 containing the block copolymer can be enhanced.

It is considered that, as a result, by phase-separation of the layer 3 containing a block copolymer, a cylinder structure oriented perpendicular to the surface of the substrate 1 can be reliably formed.

The kind of the substrate 1 is not particularly limited, as long as a BCP composition can be coated thereon. Examples thereof a substrate constituted of an organic substance, such as a metal (silicon, copper, chromium, iron, aluminum or the like), glass, titanium oxide, silica or mica; a substrate constituted of a nitride such as SiN; a substrate constituted of an oxynitride such as SiON; and a substrate constituted of an organic substance such as an acrylic resin, polystyrene, cellulose, cellulose acetate or phenol resin.

The size and the shape of the substrate 1 is not particularly limited. The substrate 1 does not necessarily need to have a smooth surface, and a substrate having various shapes can be appropriately selected for use. For example, substrates having various shapes can be used, such as a substrate having a curved surface, a plate having an uneven surface, and a thin sheet.

On the surface of the substrate 1, an inorganic and/or organic film may be provided.

As the inorganic film, an inorganic antireflection film (inorganic BARC) can be used. As the organic film, an organic antireflection film (organic BARC) can be used.

An inorganic film can be formed, for example, by coating an in organic anti-reflection film composition such as a silicon-based material on a substrate, followed by baking.

An organic film can be formed, for example, by dissolving a resin component and the like for forming the film in an organic solvent to obtain an organic film-forming material, coating the organic film-forming material on a substrate using a spinner or the like, and baking under heating conditions preferably in the range of 200 to 300° C. for 30 to 300 seconds, more preferably for 60 to 180 seconds. The organic film-forming material does not need to have susceptibility to light or electron beam like a resist film, and the organic film-forming material may or may not have such susceptibility. More specifically, a resist or a resin generally used in the production of a semiconductor device or a liquid crystal display device can be used.

Further, it is preferable that the organic film-forming material can be subjected to etching using a block copolymer pattern formed by processing the layer 3, particularly dry etching, so that, by etching the organic film using a pattern of a block copolymer, the pattern can be transferred to the organic film, and an organic film pattern can be formed. It is particularly desirable to use an organic film-forming material which can be subjected to oxygen plasma etching or the like. As such an organic film-forming material, a material conventionally used for forming an organic film such as an organic BARC can be used. Examples of such an organic film-forming material include the ARC series manufactured by NISSAN CHEMICAL INDUSTRIES, LTD., the AR series manufactured by Rohm and Haas Company, and the SWK series manufactured by Tokyo Ohka Kogyo Co., Ltd.

The method of applying the brush composition of the present invention to the substrate 1 to form a brush layer 2 is not particularly limited, and the brush layer 2 can be formed by a conventional method.

For example, the brush composition can be applied to the substrate 1 by a conventional method using a spinner or the like to form a coating film on the substrate 1, followed by drying, thereby forming a brush layer 2.

The drying method of the coating film is not particularly limited, provided it can volatilize the solvent contained in the brush composition, and a baking method and the like are exemplified. The baking temperature is preferably 80° C. to 300° C., more preferably 155° C. to 270° C., still more preferably 160° C. to 250° C., and most preferably 170° C. to 250° C. The baking time is preferably 30 seconds to 500 seconds, and more preferably 60 seconds to 400 seconds.

The above baking time and baking temperature can be arbitrarily combined.

The thickness of the brush layer 2 after drying of the coating film is preferably about 10 to 100 nm, and more preferably about 40 to 90 nm.

Before forming the brush layer 2 on the substrate 1, the surface of the substrate 1 may be cleaned in advance. By cleaning the surface of the substrate 1, the coatability of the brush composition is improved.

As the cleaning treatment, a conventional method may be used, and examples thereof include an oxygen plasma treatment, an ozone oxidation treatment, an acid alkali treatment, and a chemical modification treatment.

After forming the brush layer 2, if necessary, the brush layer 2 may be rinsed using a rinse liquid such as a solvent. By the rinsing, uncrosslinked portions within the brush layer 2 are removed, such that the affinity of the substrate for at least 1 polymer (block) constituting the block copolymer is improved, and a phase-separated structure having a cylinder structure oriented in a direction perpendicular to the surface of the substrate 1 can be reliably formed.

The rinse liquid may be any liquid capable of dissolving the uncrosslinked portions, and a solvent such as propylene glycol monomethylether acetate (PGMEA), propylene glycol monomethylether (PGME), or ethyl lactate (EL), or a commercially available thinner can be used.

After the rinsing, for volatilizing the rinse liquid, a post bake may be conducted. The temperature conditions for the post bake is preferably from 80 to 300° C., more preferably from 100 to 270° C., and still more preferably 120 to 250° C. The baking time is preferably 30 seconds to 500 seconds, and more preferably 60 seconds to 240 seconds. The thickness of the brush layer 2 after the post bake is preferably about 1 to 10 nm, and more preferably about 2 to 7 nm.

[Step (ii)]

In step (ii), on the brush layer 2, a layer 3 containing a block copolymer having a plurality of blocks bonded is formed. As the block copolymer, a block copolymer in which the aforementioned hydrophobic polymer block (b11) and the hydrophilic polymer block (b21) are bonded may be used.

The method of forming the layer 3 on the brush layer 2 is not particularly limited, and examples thereof include a method in which a BCP composition is applied to the brush layer 2 by a conventional method using spin-coating or a spinner, followed by drying. The details of the BCP composition will be described later.

The layer 3 may have a thickness satisfactory for phase-separation to occur. In consideration of the kind of the substrate 1, the structure period size of the phase-separated structure to be formed, and the uniformity of the nanostructure, the thickness is preferably 20 to 100 nm, and more preferably 30 to 80 nm.

For example, in the case where the substrate 1 is a Cu substrate, the thickness of the layer 3 is preferably 10 to 100 nm, and more preferably 30 to 80 nm.

[Step (iii)]

Step (iii), the layer 3 containing a block copolymer is phase-separated.

By heating the substrate 1 after step (ii) to conduct the anneal treatment, the block copolymer is selectively removed, such that a phase-separated structure in which at least part of the surface of the substrate 1 is exposed is formed. That is, on the substrate 1, a structure 3′ containing a phase-separated structure in which phase 3 a and phase 3 b are phase separated is produced.

The anneal treatment is preferably conducted at a temperature at least as high as the glass transition temperature of the block copolymer used and lower than the heat decomposition temperature. For example, in the case where the block copolymer is a polystyrene-polymethacrylate (PS-PMMA) block copolymer (weight average molecular weight: 5,000 to 100,000), 180 to 270° C. is preferable. The heating time is preferably 30 to 3,600 seconds.

Further, the anneal treatment is preferably conducted in a low reactive gas such as nitrogen.

By the method of producing a structure containing a phase-separated structure according to the present invention described heretofore, the phase-separation performance of the block copolymer can be enhanced, and a fine structure with a good shape can be formed, as compared to conventional lithography techniques. In addition, on the surface of the substrate, a substrate provided with a nanostructure which has the position and the orientation designed more freely can be produced. For example, the formed structure has high adhesion to the substrate, and is likely to have a phase-separated structure with a cylinder structure oriented in a direction perpendicular to the surface of the substrate.

[Optional Step]

The method of forming a structure containing a phase-separated structure according to the present invention is not limited to the above embodiment, and may include a step (optional step) other than steps (i) to (iii).

Examples of the optional steps include a step of selectively removing a phase constituted of at least one block of the plurality of blocks constituting the block copolymer contained in the layer containing the block copolymer (hereafter, referred to as “step (iv)”), and a guide pattern formation step.

Step (iv)

In step (iv), from the layer containing a block copolymer formed on the brush layer, a phase constituted of at least one block of the plurality of blocks constituting the block copolymer is selectively removed. In this manner, a fine pattern (polymeric nanostructure) can be formed.

Examples of the method of selectively removing a phase constituted of a block include a method in which an oxygen plasma treatment or a hydrogen plasma treatment is conducted on the layer containing a block copolymer.

Hereafter, among the blocks constituting the block copolymer, a block which is not selectively removed is referred to as “block P_(A)”, and a block to be selectively removed is referred to as “block P_(B)”. For example, after the phase separation of a layer containing a PS-PMMA block copolymer, by subjecting the layer to an oxygen plasma treatment or a hydrogen plasma treatment, the phase of PMMA is selectively removed. In such a case, the PS portion is the block P_(A), and the PMMA portion is the block P_(B).

FIG. 2 shows an example of one embodiment of step (iv).

In the embodiment shown in FIG. 2, by conducting oxygen plasma treatment on the structure 3′ produced on the substrate 1 in step (iii), the phase 3 a is selectively removed, and a pattern (polymeric nanostructure) constituted of phases 3 b separated from each other is formed. In this case, the phase 3 b is the phase constituted of the block P_(A), and the phase 3 a is the phase constituted of the block P_(B).

The substrate 1 having a pattern formed by phase-separation of the layer 3 containing the block copolymer as described above may be used as it is, or may be further heated to modify the shape of the pattern (polymeric nanostructure) on the substrate 1.

The heat treatment is preferably conducted at a temperature at least as high as the glass transition temperature of the block copolymer used and lower than the heat decomposition temperature. Further, the heating is preferably conducted in a low reactive gas such as nitrogen.

Guide Pattern Forming Step

In the method of forming a structure containing a phase-separated structure according to the present invention, between step (i) and step (ii), a step of forming a guide pattern on the brush layer (guide pattern forming step) may be included. In this manner, it becomes possible to control the arrangement of the phase-separated structure.

For example, in the case of a block copolymer where a random fingerprint-patterned phase separation structure is formed without using a guide pattern, by providing a trench pattern of a resist film on the surface of the brush layer, a phase separation structure arranged along the trench can be obtained. The guide pattern can be provided on the brush layer 2 in accordance with the above-described principle. Further, when the surface of the guide pattern has affinity for any of the polymers constituting the block copolymer, a phase separation structure having a cylinder structure arranged in the perpendicular direction of the surface of the substrate can be more reliably formed.

The guide pattern can be formed, for example, using a resist composition.

The resist composition for forming the guide pattern can be appropriately selected from resist compositions or a modified product thereof typically used for forming a resist pattern which have affinity for any of the polymers constituting the block copolymer. The resist composition may be either a positive resist composition capable of forming a positive pattern in which exposed portions of the resist film are dissolved and removed, or a negative resist pattern capable of forming a negative pattern in which unexposed portions of the resist film are dissolved and removed, but a negative resist composition is preferable. As the negative resist composition, for example, a resist composition containing an acid generator and a base component which exhibits decreased solubility in an organic solvent-containing developing solution under action of acid, wherein the base component contains a resin component having a structural unit which is decomposed by action of acid to exhibit increased polarity, is preferable.

When the BCP composition is cast onto the brush layer having the guide pattern formed thereon, an anneal treatment is conducted to cause phase-separation. Therefore, the resist pattern for forming a guide pattern is preferably capable of forming a resist film which exhibits solvent resistance and heat resistance.

Composition Containing a Block Copolymer (BCP Composition)

A BCP composition can be prepared by dissolving the above block copolymer in an organic development. The organic solvent is the same as defined for the organic solvent usable for the brush composition.

The amount of the organic solvent in the BCP composition is not particularly limited, and is adjusted appropriately to a concentration that enables application of a coating solution depending on the thickness of the coating film. In general, the organic solvent is used in an amount that yields a solid content for the block copolymer that is within a range from 0.2 to 70% by weight, and preferably from 0.2 to 50% by weight.

If desired, in addition to the block copolymer and the organic solvent, other miscible additives can also be added to the BCP composition. Examples of such miscible additives include additive resins for improving the performance of the layer of the brush layer, surfactants for improving the applicability, dissolution inhibitors, plasticizers, stabilizers, colorants, halation prevention agents, dyes, sensitizers, base amplifiers and basic compounds.

EXAMPLES

As follows is a description of examples of the present invention, although the scope of the present invention is by no way limited by these examples.

<Preparation of Brush Composition>

Examples 1 to 5, Comparative Examples 1 to 3

Polymeric compounds 1 and 2 were synthesized by conventional radical polymerization.

Then, each of the polymeric compounds 1 and 2 were dissolved in propylene glycol monomethyl ether acetate (PGMEA), so as to prepare the brush compositions (solid content: 1.2 wt %) of the following examples (Examples 1 to 5 and Comparative Examples 1 to 3).

TABLE 1 Resin component Organic (N) solvent (S) Example 1 (N)-4 (S)-1 [100] [8230] Example 2 (N)-5 (S)-1 [100] [8230] Example 3 (N)-6 (S)-1 [100] [8230] Example 4 (N)-7 (S)-1 [100] [8230] Example 5 (N)-8 (S)-1 [100] [8230]

TABLE 2 Resin component Organic (N) solvent (S) Comparative (N)-2 (S)-1 Example 1 [100] [8230] Comparative (N)-1 (S)-1 Example 2 [100] [8230] Comparative (N)-3 (S)-1 Example 3 [100] [8230]

In Tables 1 and 2, the reference characters indicate the following. The values in brackets [ ] indicate the amount (in terms of parts by weight) of the component added.

(N)-1:Polymeric compound 1 shown below. The compositional ratio of the copolymer (the molar ratio of the respective structural units in the polymeric compound) as determined by ¹³C-NMR was x/y/z=82/12/6; the weight average molecular weight (Mw) determined by the polystyrene equivalent value as measured by GPC was 25,000; and the polydispersity (Mw/Mn) was 1.65.

(N)-2:Polymeric compound 2 shown below. The compositional ratio of the copolymer (the molar ratio of the respective structural units in the polymeric compound) as determined by ¹³C-NMR was x/y=93/7; the weight average molecular weight (Mw) determined by the polystyrene equivalent value as measured by GPC was 25,000; and the polydispersity (Mw/Mn) was 1.64.

(N)-3:Polymeric compound 2 shown below. The compositional ratio of the copolymer (the molar ratio of the respective structural units in the polymeric compound) as determined by ¹³C-NMR was x/y=94/6; the weight average molecular weight (Mw) determined by the polystyrene equivalent value as measured by GPC was 25,000; and the polydispersity (Mw/Mn) was 1.64.

(N)-4:Polymeric compound 2 shown below. The compositional ratio of the copolymer (the molar ratio of the respective structural units in the polymeric compound) as determined by ¹³C-NMR was x/y=95/5; the weight average molecular weight (Mw) determined by the polystyrene equivalent value as measured by GPC was 25,000; and the polydispersity (Mw/Mn) was 1.64.

(N)-5:Polymeric compound 2 shown below. The compositional ratio of the copolymer (the molar ratio of the respective structural units in the polymeric compound) as determined by ¹³C-NMR was x/y=96/4; the weight average molecular weight (Mw) determined by the polystyrene equivalent value as measured by GPC was 25,000; and the polydispersity (Mw/Mn) was 1.67.

(N)-6:Polymeric compound 2 shown below. The compositional ratio of the copolymer (the molar ratio of the respective structural units in the polymeric compound) as determined by ¹³C-NMR was x/y=97/3; the weight average molecular weight (Mw) determined by the polystyrene equivalent value as measured by GPC was 25,000; and the polydispersity (Mw/Mn) was 1.67.

(N)-7:Polymeric compound 2 shown below. The compositional ratio of the copolymer (the molar ratio of the respective structural units in the polymeric compound) as determined by ¹³C-NMR was x/y=98/2; the weight average molecular weight (Mw) determined by the polystyrene equivalent value as measured by GPC was 25,000; and the polydispersity (Mw/Mn) was 1.68.

(N)-8:Polymeric compound 2 shown below. The compositional ratio of the copolymer (the molar ratio of the respective structural units in the polymeric compound) as determined by ¹³C-NMR was x/y=99/1; the weight average molecular weight (Mw) determined by the polystyrene equivalent value as measured by GPC was 25,000; and the polydispersity (Mw/Mn) was 1.67.

(S)-1: propyleneglycol monomethyletheracetate (PGMEA).

(Production of Structure Containing Phase-Separated Structure)

[Step (i)]

Subsequently, each of the brush compositions shown in Tables 1 and 2 (Examples 1 to 5 and Comparative Examples 1 to 3) was applied to an 8-inch silicon wafer using a spinner, followed by baking and drying at a baking temperature and a baking time shown in Table 3, so as to form a brush layer.

The brush layer was rinsed with OK73 thinner (product name; manufactured by Tokyo Ohka Kogyo Co., Ltd.), so as to remove the uncrosslinked portions and the like of the random copolymer. Then, baking was conducted at 250° C. for 60 seconds.

[Water Contact Angle on the Surface of the Brush Layer]

A water droplet was dripped onto the surface of the brush layer, and DROP MASTER-700 apparatus (a product name, manufactured by Kyowa Interface Science Co. Ltd.) was used to measure the contact angle (static contact angle) (contact:angle measurement:water 2 μL). The measured value is indicated under “contact angle (°)” in Table 3.

[Step (ii)]

Subsequently, a PGMEA solution of a PS-PMMA block copolymer (PS/PMMA compositional ratio (molar ratio)=55/45; Mw=42,400; Mw/Mn=1.07; period=26 nm) (block copolymer concentration: 2 wt %) was spin-coated (number of rotation: 1,500 rpm; 60 seconds) to cover the brush layer formed on the organic anti-reflection film.

Then, the substrate having the PGMEA solution of the PS-PMMA block copolymer coated thereon was baked and dried at 90° C. for 60 seconds, so as to form a PS-PMMA block copolymer layer having a film thickness of 30 nm.

[Step (iii)]

Next, in a nitrogen gas stream, an anneal treatment was conducted by heating at 210° C. for 300 seconds, so as to phase-separate the PS-PMMA block copolymer layer into a phase constituted of PS and a phase constituted of PMMA, thereby forming a phase-separated structure.

As a result, in each of the examples, a structure containing a phase-separated structure was formed on the brush layer. In the case of using the brush compositions of Examples 1 to 5, a pattern in which both a perpendicular vertical cylinder pattern and a horizontal cylinder pattern were present was formed. In the case of using the brush compositions of Comparative Examples 1 to 3, a perpendicular vertical cylinder pattern was formed.

[Step (iv)]

An oxygen plasma treatment (200 mL/min, 40 Pa, 40° C., 200 W, 20 seconds) was conducted on the silicon (Si) wafer having the phase-separated structure formed thereon using TCA-3822 (manufactured by Tokyo Ohka Kogyo Co., Ltd.), so as to selectively remove the phase constituted of PMMA.

[Evaluation of Phase-Separation Performance]

The surface of the obtained substrate (phase-separation state) was observed with a scanning electron microscope (SEM) (CG5000 manufactured by Hitachi High-Technologies).

As a result of the observation, the case where a pattern in which both a perpendicular vertical cylinder pattern and a horizontal cylinder pattern were present with more horizontal cylinders was observed was evaluated “A”, the case where a pattern in which both a perpendicular vertical cylinder pattern and a horizontal cylinder pattern were present was observed was evaluated “B”, and the case where only a perpendicular vertical cylinder pattern was observed was evaluated “C”. The results are indicated under “phase-separation performance” in Table 3.

In the present specification, formation of a horizontal cylinder pattern indicates that the brush composition has a higher affinity for the hydrophobic polymer block.

TABLE 3 Baking Baking Contact temperature time angle Phase-separation (° C.) (Seconds) (°) performance Example 1 210 60 87.7 B Example 2 210 60 88.0 B Example 3 210 60 87.7 A Example 4 210 60 87.7 A Example 5 210 60 87.8 A Comparative 210 60 82.5 C Example 1 Comparative 210 60 82.5 C Example 2 Comparative 210 60 84.2 C Example 3

From the results shown in Table 3, it was confirmed that, in the cases where the brush compositions of Examples 1 to 5 adopting the present invention were used, the phase-separation performance of the block copolymer can be improved, as compared to the cases where the brush compositions of Comparative Examples 1 to 3 outside the scope of the present invention were used.

In addition, with respect to the brush compositions of Examples 1 to 5, it was confirmed that, in the production of a structure containing a phase-separated structure, the water contact angle is large, and horizontal cylinder pattern was formed. Therefore, it was confirmed that the brush compositions of Examples 1 to 5 has a higher affinity for the hydrophobic polymer block.

In the present examples, the phase-separation performance is tested in the case where the brush composition of the present invention is applied to a substrate, and a block copolymer is applied to the brush composition. The aim of the test is to test the affinity for the block copolymer, and by no means limit other applications of the brush composition. For example, even in the case where the brush composition of the present invention is applied to a substrate to form a brush layer, and a guide pattern is formed on the brush layer using a resist composition or the like, it is considered that the phase-separation performance can be improved as compared to the cases where the brush compositions of Comparative Examples 1 to 3 outside the scope of the present invention are used.

While preferred embodiments of the invention have been described and illustrated above, it should be understood that these are exemplary of the invention and are not to be considered as limiting. Additions, omissions, substitutions, and other modifications can be made without departing from the spirit or scope of the present invention. Accordingly, the invention is not to be considered as being limited by the foregoing description, and is only limited by the scope of the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

1: Substrate

2: Brush layer

3: Layer

3 a: Phase

3 b: Phase 

What is claimed is:
 1. A method of producing a structure containing a phase-separated structure, the method comprising: applying a brush composition to a substrate to form a brush layer; forming a layer containing a block copolymer on the brush layer; and phase-separating the layer containing the block copolymer, wherein the brush composition comprises a resin component (N) consisting of a hydrophobic structural unit (Nx) represented by general formula (Nx-1) shown below and a hydrophilic structural unit (Ny) represented by general formula (Ny-1-1) shown below, wherein the amount of the structural unit (Ny) within the resin component (N) is 3 mol % or less, and wherein the amount of the structural unit (Nx) within the resin component (N) is 97 mol % or more;

wherein R represents a hydrogen atom, an alkyl group of 1 to 5 carbon atoms or a halogenated alkyl group of 1 to 5 carbon atoms; R¹ represents a halogen atom, or a linear, branched or cyclic hydrocarbon group of 1 to 20 carbon atoms optionally containing an oxygen atom, a halogen atom or a silicon atom, or a combination of the linear, branched or cyclic hydrocarbon group; and n represents an integer of 0 to 5;

wherein R represents a hydrogen atom, an alkyl group of 1 to 5 carbon atoms or a halogenated alkyl group of 1 to 5 carbon atoms; and Y¹ represents an alkyl group of 1 to 5 carbon atoms wherein the block copolymer is a polystyrene-polymethyl methacrylate (PS-PMMA) block copolymer. 